Christmas tree assembly with high integrity pipeline protection system

ABSTRACT

A mineral extraction system that includes a christmas tree. The christmas tree includes a valve that controls the flow of hydrocarbons through the christmas tree. A subsea control module couples to the christmas tree. The subsea control module controls the valve to control the flow of hydrocarbons through a conduit in the christmas tree. A high integrity pipeline protection system integrated with the subsea control module. The high integrity pipeline protection system includes a first pressure sensor that emits a first signal indicative of pressure in the conduit. A high integrity pipeline protection controller that receives the first signal indicative of the pressure and automatically controls operation of the valve in response to the pressure exceeding a threshold pressure.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a non-provisional application claiming priority to U.S. provisional application No. 62/819,719, entitled “CHRISTMAS TREE ASSEMBLY WITH INTEGRATED HIPPS FUNCTIONALITY,” filed Mar. 18, 2019, which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure relates generally to determining physical addresses.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.

Fluids, such as hydrocarbons, may be extracted from subsurface reservoirs and transported to the surface for commercial sales. These hydrocarbons may be used in the power industry, transportation industry, manufacturing industry, and other applicable industries. In order to extract these fluids, a well may be drilled into the ground to a subsurface reservoir, and equipment may be installed in the well and on the surface to facilitate extraction of the fluids. In some cases, the wells may be offshore (e.g., subsea), and the equipment may be disposed underwater, on offshore platforms, and/or on floating systems.

As the fluids flow out of the well, the pressure of the fluids may change. High integrity pipeline protection systems (HIPPS) are used to monitor the flow of fluids exiting the wellhead and block over-pressurization of the pipe or flowlines that carry the fluids away from the wellhead. These HIPP systems are installed independently of the christmas tree that connects to the wellhead. That is HIPP systems are either included as a separately dedicated manifold or as part of the overall production manifold assembly.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In one embodiment, a mineral extraction system that includes a christmas tree. The christmas tree includes a valve that controls the flow of hydrocarbons through the christmas tree. A subsea control module couples to the christmas tree. The subsea control module controls the valve to control the flow of hydrocarbons through a conduit in the christmas tree. A high integrity pipeline protection system integrated with the subsea control module. The high integrity pipeline protection system includes a first pressure sensor that emits a first signal indicative of pressure in the conduit. A high integrity pipeline protection controller that receives the first signal indicative of the pressure and automatically controls operation of the valve in response to the pressure exceeding a threshold pressure.

In another embodiment, a subsea control module that includes a first controller that controls a christmas tree valve that controls a flow of hydrocarbons out of the christmas tree. A high integrity pipeline protection system that includes a first pressure sensor that emits a first signal indicative of a pressure in a conduit of the christmas tree. A first high integrity pipeline protection controller that receives the first signal indicative of the pressure and automatically controls operation of the valve in response to the pressure exceeding a threshold pressure.

In another embodiment, a subsea control module that includes a first controller that controls a christmas tree valve that controls a flow of hydrocarbons out of a christmas tree. A second controller controls the christmas tree valve that controls the flow of hydrocarbons out of the christmas tree. A high integrity pipeline protection system that includes a first pressure sensor that emits a first signal indicative of a pressure in a conduit of the christmas tree. A second pressure sensor emits a second signal indicative of the pressure in the conduit of the christmas tree. A first high integrity pipeline protection controller receives the first signal and the second signal and automatically controls operation of the christmas tree valve in response to the first signal and the second signal. A second high integrity pipeline protection controller receives the first signal and the second signal and automatically controls operation of the christmas tree valve in response to the first signal and the second signal.

Various refinements of the features noted above may exist in relation to various aspects of the present disclosure. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. The brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of embodiments of the present disclosure without limitation to the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic view of a mineral extraction system with a high integrity pipeline protection system integrated into a christmas tree assembly, in accordance with embodiments described herein;

FIG. 2 is a perspective view of a christmas tree assembly with an integrated high integrity pipeline protection system, in accordance with embodiments described herein;

FIG. 3 is a schematic view of a subsea control module with an integrated high integrity pipeline protection system, in accordance with embodiments described herein; and

FIG. 4 is a schematic of a mineral extraction system with a high integrity pipeline protection system integrated into a christmas tree assembly, in accordance with embodiments described herein.

DETAILED DESCRIPTION

Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.

The description below describes a mineral extraction system with a christmas tree and a subsea control module. Integrated into the subsea control module and christmas tree assembly is a high integrity pipeline protection (HIPP) system that automatically closes one or more valves on the christmas tree in response to a hydrocarbon fluid pressure exceeding a threshold pressure. By integrating the HIPP system into the christmas tree and the subsea control module (e.g., christmas tree subsea control module), the mineral extraction system does not need installation of a separate HIPP system module to control hydrocarbon flow into a flowline or pipeline that carries the hydrocarbons away from the well. This may reduce the number of components of the mineral extraction system, installation time, and other resources.

FIG. 1 is a schematic view of a mineral extraction system 10 with a high integrity pipeline protection (HIPP) system 12 integrated into a christmas tree assembly 14. As explained above, HIPP systems are typically deployed as a separate module or as part of the overall production manifold assembly. By integrating the HIPP system 12 into the christmas tree 14 (e.g., christmas tree assembly), the mineral extraction system 10 may be deployed more rapidly and may reduce the expense of producing a separately deployable subsea module.

The christmas tree 14 couples to wellhead 16 to form a subsea station 18 that extracts oil and/or natural gas from the sea floor 20 through the well 22. In some embodiments, the mineral extraction system 10 may include multiple subsea stations 18 that extract oil and/or gas from respective wells 22. After passing through the christmas tree 14, the hydrocarbons (e.g., oil, gas) flow through jumper cables 24 to a pipeline end termination and/or a pipeline end manifold 26. The pipeline end manifold 26 connects to one or more flowlines 28. The flowlines 28 enable oil and/or gas to flow from the wells 22 to the platform 30. In some embodiments, the flowlines 28 may extend from the subsea stations 18 to another facility such as a floating production, storage and offloading unit (FPSO), or a shore-based facility. In addition to flow lines that carry hydrocarbons away from the wells 22, the mineral extraction system 10 may include lines or conduits 31 that supply fluids, as well as carry control and data lines to the subsea equipment. These flowlines 31 connect to a distribution module 32, which in turn couples to the subsea stations 18 with lines 34.

FIG. 2 is a perspective view of a christmas tree 14 with the HIPP system 12. In operation, the HIPP system 12 protects the jumpers 24 and flowlines 28 from hydrocarbons flowing through the mineral extraction system 10 at a pressure greater than a threshold pressure. For example, the jumpers 24 and flowlines 28 may have a specific pressure rating or an optimal pressure capacity. In order to block hydrocarbons from entering the jumpers 24 and flowlines 28 at a pressure greater than the threshold pressure, the HIPP system 12 monitors the pressure of the hydrocarbons flowing through the christmas tree 14 and closes one or more valves 50 (e.g., christmas tree valves) using one or more actuators 52. In order to detect the pressure of the hydrocarbons, the HIPP system 12 includes pressure sensors 54. The pressure sensors 54 couple to a HIPP system controller 56 and emit signals indicative of the hydrocarbon pressure. The HIPP system controller 56 receives these signals and detects the pressures sensed by the different pressure sensors 54.

The HIPP system controller 56 may include a processor 58 and a memory 60. The processor 58 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processor 58 may include one or more reduced instruction set computer (RISC) processors.

The memory 60 may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory 60 may store a variety of information and may be used for various purposes. For example, the memory 60 may store processor executable instructions (e.g., firmware or software) for the processor 58 to execute, such as instructions for processing the signals from the sensors 54. The storage device(s) (e.g., nonvolatile memory) may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The storage device(s) may store data, instructions, and any other suitable data.

In some embodiments, the controller 56 may include a logic solver that compares feedback from the pressure sensors 54 to determine if the pressure of the hydrocarbons exceeds the threshold pressure. For example, if both of the pressure sensors 54 indicate the pressure of the hydrocarbons exceeds the threshold pressure, then the controller 56 shuts the valve(s) 50. But if one of the pressure sensors 54 indicates that the pressure of the hydrocarbons is less than the threshold pressure, the controller 56 may not close the valve(s) 50. This kind of logic solving may differ depending on the number of pressure sensors 54. For example, if the HIPP system 12 includes 3, 4, 5, 6, 7, 8, 9, 10 or more pressure sensors 54, the controller 56 may shut the valve(s) 50 in response to a plurality of the pressure sensors 54, half of the pressure sensors 54, and/or more than half of the pressure sensors 54 indicating that the pressure exceeds the threshold pressure.

FIG. 3 is a schematic view of a subsea control module (SCM) 80 with an integrated high integrity pipeline protection (HIPP) system 12. As illustrated, the SCM 80 includes a first subsea electronics module (SEM) 82 and a second SEM 84 to provide redundant control of the valves 50 as well as redundant monitoring of the pressure sensors 54. The first SEM 82 (e.g., SEM A) includes a first controller 86 (e.g., controller A), a first power supply 88 (e.g., power supply A), and a first HIPP controller 90 (e.g., HIPP controller A). The second SEM 84 similarly includes a second controller 92 (e.g., controller B), a second power supply 94 (e.g., power supply B), and a second HIPP controller 96 (e.g., HIPP controller B). It should be understood, that each controller mentioned above may include one or more processors and one or more memories. In operation, the one or more processors execute instructions stored on the one or more memories.

During operation, the SCM 80 enables an operator to actively control the valves 50 while also providing automatic shutoff or closure of the valves 50 in the event of excessive pressure detection in the conduit 98. It is the HIPP system 12 that provides the ability to automatically close the valves 50 without operator intervention. The SCM 80 enables an operator to actively control the valves 50 using the controllers 86 and 92. As illustrated, the controllers 86 and 92 couple to a solenoid driver module 100 that receives power from power supplies 88 and 94. The controllers 86 and 92 are configured to receive instructions from an operator to control the power to first and second coils 102 and 104. When energized the coils 102 and 104 open the solenoid operated direct control valve 106 (SODCV). For example, the SODCV 106 may only open if both coils 102, 104 are energized. In other words, the SODCV 106 may be a fail close valve. The opening of the SODCV 106 enables pressurized hydraulic fluid to flow from a hydraulic fluid supply 108 to the actuators 52, which in turn open the valves 50. To close the valves 50, the controllers 86 and 92 instruct the solenoid driver module 100 to block power to the coils 102 and 104, which then closes the SODCV 106. The closing of the SODCV 106 blocks hydraulic fluid flow to the actuators 52, which then lack the power to keep the valves 50 open (e.g., fail close valves 50). The valves 50 therefore close in response to de-energizing of the coils 102 and 104. In some embodiments, the closure of the SODCV 106 opens another line 110 that sends the hydraulic fluid flowing from the hydraulic fluid supply 108 back to the hydraulic fluid supply 108.

The HIPP controllers 90 and 96 similarly control the de-energizing of the coils 102 and 104 but in response to sensor feedback. As explained above, the HIPP system 12 includes pressure sensors 54 (e.g., 1, 2, 3, 4, 5, or more). The pressure sensors 54 may be upstream and/or downstream of the valves 50. For example, all of the pressure sensors 54 may be upstream from the valves 50, all downstream from the valves 50, or some may be upstream and others downstream from one or more of the valves 50. In operation, the pressure sensors 54 emit signals indicative of the pressure of the hydrocarbons in the conduit 98. The pressure sensors 54 couple to the HIPP controller 90 and 96, which receive these signals and detects the pressures sensed by the pressure sensors 54. In some embodiments, the controllers 90 and 96 include logic solvers that compares feedback from the pressure sensors 54 to determine if the pressure of the hydrocarbons exceeds a threshold pressure. For example, if two or more of the pressure sensors 54 indicate the pressure of the hydrocarbons exceeds the threshold pressure, then the controller 56 shuts the valve(s) 50. This kind of logic solving may differ depending on the number of pressure sensors 54. For example, if the HIPP system 12 includes 2, 3, 4, 5, 6, 7, 8, 9, 10 or more pressure sensors 54, the controller 56 may shut the valve(s) 50 in response to a plurality of the pressure sensors 54, half of the pressure sensors 54, and/or more than half of the pressure sensors 54 indicate that the pressure exceeds the threshold pressure.

By detecting the pressure of the hydrocarbons in the conduit 98, the HIPP system 12 protects the jumpers 24 and flowlines 28 from hydrocarbons flowing through the mineral extraction system 10 at a pressure greater than a threshold pressure. For example, the jumpers 24 and flowlines 28 may have a specific pressure rating or an optimal pressure capacity. More specifically, if the controllers 90 and 96 detect that the pressure in the conduit 98 is greater than the threshold pressure, the controllers 90 and 96 may open respective switches 112 and 114 to block the flow of power from the solenoid driver module 100 to the respective coils 102 and 104. The switches 112 and 114 may be solid state relays, solid state switches, electro-mechanical relays among others. As explained above, de-energizing the coils 102 and 104 closes the SODCV 106. The closing of the SODCV 106 blocks hydraulic fluid flow to the actuators 52, which then lack the power to keep the valves 50 open. The valves 50 therefore close in response to de-energizing of the coils 102 and 104. The closure of the valves 50 in turn block hydrocarbons at a pressure in excess of the threshold pressure from flowing through the downstream jumpers 24 and flowlines 28.

In some embodiments, the valves 50 may not be hydraulically actuated valves. For example, they may be electrically actuated valves. These valves may similarly be fail close valves that close when the HIPP controllers 90 and 96 open the circuits 112 and 114.

FIG. 4 is a schematic of a mineral extraction system 130 with a high integrity pipeline protection (HIPP) system 132 (e.g., HIPP system 12) integrated into a christmas tree 134 (e.g., christmas tree assembly). By integrating the HIPP system 132 into the christmas tree 134, the mineral extraction system 130 may exclude a separate HIPP system or HIPP system module placed between the christmas tree 134 and a pipeline or flowline 136, between the christmas tree 134 and flowline jumpers 138, and/or between the christmas tree 134 and a PLEM (pipeline end manifold) or PLET (pipeline end termination) 140. This may reduce the number of components of the mineral extraction system 130, installation time, and other resources.

The technical effects of the systems and methods described herein include a christmas tree with an integrated HIPP system that controls the flow of hydrocarbons through the christmas tree in response to a pressure in excess of a threshold pressure.

As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

Finally, the techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f). 

1. A mineral extraction system, comprising: a christmas tree, the christmas tree comprising: a valve configured to control a flow of hydrocarbons through the christmas tree; a subsea control module coupled to the christmas tree, wherein the subsea control module is configured to control the valve to control the flow of hydrocarbons through a conduit in the christmas tree; a high integrity pipeline protection system integrated with the subsea control module, the high integrity pipeline protection system comprising: a first pressure sensor configured to emit a first signal indicative of a pressure in the conduit; and a high integrity pipeline protection controller configured to receive the first signal and to automatically control operation of the valve in response to the pressure exceeding a threshold pressure.
 2. The system of claim 1, wherein subsea control module comprises a first controller configured to control the valve in response to feedback from an operator.
 3. The system of claim 2, wherein the subsea control module comprises a power supply configured to provide power to a solenoid driver module.
 4. The system of claim 3, comprising a coil configured to receive power from the solenoid driver module, wherein the coil controls operation of a solenoid operated direct control valve to control the valve.
 5. The system of claim 1, comprising an actuator coupled to the valve, wherein the actuator is configured to receive hydraulic fluid to block closing of the valve.
 6. The system of claim 1, comprising a second pressure sensor, the second pressure sensor is configured to emit a second signal indicative of the pressure in the conduit.
 7. The system of claim 6, wherein the first pressure sensor and the second pressure sensor are upstream from the valve.
 8. The system of claim 1, comprising a flowline coupled to the christmas tree, wherein the mineral extraction system excludes a second high integrity pipeline protection system between the christmas tree and the flowline.
 9. A subsea control module comprising: a first controller configured to control a christmas tree valve that controls a flow of hydrocarbons out of a christmas tree; a high integrity pipeline protection system, the high integrity pipeline protection system comprising: a first pressure sensor configured to emit a first signal indicative of a pressure in a conduit of the christmas tree; and a first high integrity pipeline protection (HIPP) controller configured to receive the first signal indicative of the pressure and to automatically control operation of the christmas tree valve in response to the pressure exceeding a threshold pressure.
 10. The subsea module of claim 9, comprising a second controller configured to control the christmas tree valve that controls the flow of hydrocarbons out of the christmas tree.
 11. The subsea module of claim 9, comprising a solenoid driver module configured to supply power to a first coil and a second coil.
 12. The subsea module of claim 11, comprising a solenoid operated direct control valve, wherein the first coil and the second coil are configured to maintain the solenoid operated direct control valve in an open position while energized.
 13. The subsea module of claim 9, comprising a second pressure sensor configured to emit a second signal indicative of the pressure.
 14. The subsea module of claim 13, wherein the first HIPP controller is configured to use a logic solver to determine whether the pressure in the conduit exceeds the threshold pressure using the first signal and the second signal.
 15. The subsea module of claim 13, wherein the second HIPP controller is configured to use a logic solver to determine whether the pressure in the conduit exceeds the threshold pressure using the first signal and the second signal.
 16. A subsea control module comprising: a first controller configured to control a christmas tree valve that controls a flow of hydrocarbons out of a christmas tree; a second controller configured to control the christmas tree valve that controls the flow of hydrocarbons out of the christmas tree; a high integrity pipeline protection system, the high integrity pipeline protection system comprising: a first pressure sensor configured to emit a first signal indicative of a pressure in a conduit of the christmas tree; a second pressure sensor configured to emit a second signal indicative of the pressure in the conduit of the christmas tree; a first high integrity pipeline protection controller configured to receive the first signal and the second signal and to automatically control operation of the christmas tree valve in response to the first signal and the second signal; and a second high integrity pipeline protection controller configured to receive the first signal and the second signal and to automatically control operation of the christmas tree valve in response to the first signal and the second signal.
 17. The subsea module of claim 16, comprising a solenoid driver module configured to supply power to a first coil and a second coil.
 18. The subsea module of claim 17, comprising a solenoid operated direct control valve, wherein the first coil and the second coil are configured to maintain the solenoid operated direct control valve in an open position while energized.
 19. The subsea module of claim 17, comprising a first power supply and a second power supply, wherein the first power supply and the second power supply are configured to supply power to the solenoid driver module.
 20. The subsea module of claim 16, wherein the first HIPP controller and the second HIPP controller are configured to use a logic solver to determine whether the pressure in the conduit exceeds a threshold pressure using the first signal and the second signal. 